Member Profile - James' GT spec B Wagon - GTB013

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Re: Member Profile - James' GT spec B Wagon - GTB013

Postby jamescd » Wed Oct 02, 2019 10:17 pm

Fitted the Perrin cover
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Still have more to do on the maf scaling

Was driving the other week and thought the car had sprung another oil leak as a lot of smoke was coming from under the bonnet. Couldn't see an obvious leak and got it home. Jacked the car up and found that my front driver's side driveshaft had split the inner boot. While doing this I also discovered that my tyres had some severe inner wear. I ordered some new tyres and drove the car sparingly.

The new tyres arrived yesterday, I went with Nankang NS2Rs in 235/40R18, first impressions are good, will be interested to see how they perform.

I picked up a second-hand driveshaft on the weekend, and today fitted that.

Took the old one out. It was completely stuffed.
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While it was out I decided to heat wrap the section of the exhaust that runs by the driveshaft in an effort to reduce heat fatiguing the rubber boot.
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Shaft in, didn't want to go into the hub nicely, but got it in the end.
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New axle nut on.
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Another bay pic, just for the sake of it.
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I have also adjusted all the coilovers to sit a little higher, I loved it low, but it didn't love me, something suspension related in hard turns while in reverse, and I scraped the bottom of the fmic on things, so it had to go up a little.

A few things to do
- New clutch pedal with bearing and billet clevis
- Re-run underseat sub wiring as it was causing a short, have left it unplugged in the interim
- Do some long drives to finish the maf scaling

Otherwise it's pretty right for the time-being, just small things
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Re: Member Profile - James' GT spec B Wagon - GTB013

Postby jamescd » Tue Nov 19, 2019 2:29 pm

Bit of an updoot.

I finally got around to fitting my clutch pedal clevis.
It is a much bulkier unit than the stock one
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I had a full new pedal assembly which had the bearing fit.
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Clutch master unbolted
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Old and new clutch pedal assemblies
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The part that threads into the clevis was pretty stuffed, so I pulled it out enough to be able to re-thread the threads.
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Back in the car
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Connected
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I have also had problems with the turbo oil return since I fit the turbo setup.
I decided that I was sick of it leaking and that I would fix it properly so I would only have to do it once.
In this thinking I bought a Torque Solution oil drain kit. ($200 how ya goin)
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The first step was to remove the stock oil drain tube from the head
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To do this, I put a long piece of bar into the drain and wiggled it side to side and pried the tube out at the same time
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New fitting in
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Hose attached to the fitting on the turbo and the block
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DONE!





But it wasn't done.

The hose had a kink in it and was causing oil to back up and leak out of the turbo.
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Do all of the above steps in reverse.
Shorten the hose.
Attach the fitting, this time unbolting the up-pipe each time so it's easier to screw into the fitting.
Bolt up the up-pipe.
Try to bolt on the turbo.
The hose kinks again.

Do the same as above with a shorter hose.
The turbo won't fit because the hose is too short.

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Cry.




Realise that the short hose won't fit because it's fouling on the up-pipe bracket.
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Try using an extension fitting to clear the bracket.
Fail.

Pull out the angle grinder and chop some of the bracket off.
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Reinstall everything with the chopped bracket.
The hose kinks now because of the angle of the top fitting.
Buy a straight fitting.
Fit the straight fitting.
It fits first time.
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Go for a drive.
Car blows a shit load of smoke on boost and leaks oil from the bottom of the engine.

Cry some more.

Take it to a mechanic to find out what's wrong with it.

- The head fitting is leaking
- The up-pipe v-band isn't on correctly
- The turbo is at too much of an angle causing oil to build up and not drain

Pull everything back out.

Clock the turbo as much as possible without the drain fouling on the up-pipe.
Pull the fitting and put a bead of ultra black gasket maker around the base before reinstalling.
Wait for the ultra black to cure.
Reinstall everything.
Realise once again that the hose is the wrong length.
It's also fouling on the up-pipe bracket again.
Chop the bracket some more.
It fits.
Buuuuuut, the hose is the wrong length again.
Play with the hose more.

Finally, get it to fit.

Properly reinstall everything.

Resent the fact that if I had just bought some hydraulic hose and replaced the old drain hose it would have worked straight away with none of the issues and a lot less expense.

Drive the car.
It now works, still blows a little oil, but not much. It also doesn't leak from the fitting anymore.

It's at the point where I can't fix it any more at home, and I also need to be able to drive to Sydney next week for national meet. It has also been about a two week ordeal fitting/fixing this and I am very much over trying to sort out this same problem over and over again.

Edit: it may sound like I'm just complaining, but I just checked and I legitimately started work on the oil drain on the 3rd of November and it's now the 19th. It was a nightmare of a job, made worse by some bits of the kit just not working.
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Re: Member Profile - James' GT spec B Wagon - GTB013

Postby bigBADbenny » Tue Nov 19, 2019 4:25 pm

Not ideal but could you use a slightly longer hose and clock the lower (and upper?) fitting?
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Re: Member Profile - James' GT spec B Wagon - GTB013

Postby jamescd » Tue Nov 19, 2019 9:08 pm

The issue is that I can't change the angle of the core to be any more up/down as it's at the point where the v-band only just clears it to bolt the up-pipe on, any more and the turbo won't bolt on.
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Re: Member Profile - James' GT spec B Wagon - GTB013

Postby bigBADbenny » Wed Nov 20, 2019 4:43 am

Full on, what’s the turbo kit?
Maybe there’s a better grade hose available that will bend and not kink? Ask Pirtek?
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Re: Member Profile - James' GT spec B Wagon - GTB013

Postby jamescd » Wed Nov 20, 2019 8:46 am

It's a custom made setup, but it shouldn't be having issues as it was fine when the original drain fitting was attached.
I also don't really want to do a whole lot more to the setup for the moment, I'll run it as is until I am a bit more inspired to fix it.
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Re: Member Profile - James' GT spec B Wagon - GTB013

Postby bigBADbenny » Wed Nov 20, 2019 10:43 am

Sweet! I did miss the all works now part :P...
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Re: Member Profile - James' GT spec B Wagon - GTB013

Postby jamescd » Sat Nov 23, 2019 12:04 pm

So, while doing all of the testing and troubleshooting I forgot that I had topped up the oil with a fair bit of 5w-30 (as it was what I had).
I was planning on changing it before the drive to national meet anyway, but I changed it this morning as the car got quite smokey last night once it was warm. So far, the thicker oil seems to have fixed the problems. Hopefully it will stay that way.

Edit: it works for general driving and some boosting, but hills are a different story. Still plenty of smoke after the sustained load of a hill.
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Re: Member Profile - James' GT spec B Wagon - GTB013

Postby jamescd » Mon Feb 24, 2020 12:22 am

Well it has been ages since an update and I've done a couple of new things.

Some things stay the same, the oil return is still leaking, so I'll be returning it to a stock setup with some good quality hose.
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Seriously, everywhere I park, I leave this


Starting vaguely where the last post ended, the car made it up to Sydney for the national meet. It wasn't perfect, but it cruised along the highway nicely.

I bought a lot while at the national meet, I also delivered a lot of things back to friends.
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One of the things I bought was a Carbing front strut brace
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Unfortunately when I went to fit this I discovered that the brake master cylinder stopper fouled on the turbo.

I bought a Cusco Handbrake button to replace the black ebay one I had before.
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I also bought a Zero Sports rear strut brace, fortunately this fit.
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I sold the Carbing, and sad that I had to part with such a cool JDM item, I ended up buying an aluminium Corazon item from Japan (more on that later).



I've had a wobble since I got my new tyres fitted, I also did the driveshaft at the same time, so I figured one of those was the problem. I got my tyres balanced, only to find out that one of my wheels was buckled. I can't see it in the photo, but it's there.
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$165 later, no buckles.

Despite no buckles, I still have a wobble.



For some time I have wanted a subwoofer for the stock location, I finally bit the bullet and got a Kicker CompRT unit.
With a spacer it fit nicely.
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A $50 second hand amp to power it
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It sounds good, but it has uncovered a lot of rattles.


I scored a JDM coin holder fuse cover (with the clip, so it's not all floppy)
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Since installing the turbo and intercooler setup, the intercooler has been wonky, this has annoyed me.
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To fix this I made a bracket which mounted to the crash bar mounts.
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Some clearancing was needed so that the intercooler pipes didn't rub
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With the bracket done I installed it on the car
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I also finally got around to fitting the Corazon strut brace, I genuinely can't believe how light it is, when I picked it up from the post office I was concerned it was an empty box.
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I have been chipping away at small jobs, but the oil return line has really taken a big chunk out of my love for working on this car, hopefully I'll be fixing that next weekend and I'll have a nice car to drive and live with again.
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Re: Member Profile - James' GT spec B Wagon - GTB013

Postby bigBADbenny » Mon Feb 24, 2020 5:02 am

From a post on stav-tech on Facebook: some aftermarket turbo drain fittings are too small to properly drain the turbo.

https://m.facebook.com/watch/?v=624783081342669&_rdr

Use a stock turbo drain fitting, or stock like, or drill out the supplied drain fitting to oem diameter if possible.

Obviously the other end needs to be the same internal diameter, an just use reinforced drainage hose and clamps.

Also check if your pcv is clean and not sticking shut, pressurising the crank case.
Clean it out with thinners or replace it with a new one.
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Re: Member Profile - James' GT spec B Wagon - GTB013

Postby jamescd » Mon Feb 24, 2020 9:21 am

Yeah, I know that the turbo side fitting isn't up to scratch, I know the smoke is because it's not draining properly. The leak itself though is because of the fitting that goes into the block, it just straight up leaks. So mostly I'm reverting to stock because of that.

When I redo the engine/heads, I'll likely weld an AN fitting to the head so that it won't leak, and I can ensure that everything is the right size then.
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Re: Member Profile - James' GT spec B Wagon - GTB013

Postby bigBADbenny » Mon Feb 24, 2020 9:56 am

As stav stated, stock stuff works especially for turbo drain.

If you still have excessive supply, a turbosmart oil pressure reg (opr) set to either journal or ball bearing pressure as required for your turbo chra is a fairly affordable option.
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Re: Member Profile - James' GT spec B Wagon - GTB013

Postby jamescd » Thu Mar 05, 2020 8:08 pm

I have started to pull the Torque Solution drain out, and while doing so I have done some measurements of the internal diameters mostly for curiosities sake, but it is mildly interesting if you're into that kind of thing.


Diameter Area
Stock Drain Top 12.6mm 124.69
Stock Drain Head 11.8mm 109.36
Stock type turbo drain fitting 13.4mm 141.03
AN-10 hose 14mm 153.94
AN-10 fitting 11.3mm 100.29
TS AN turbo fitting 12.45mm 121.74
TS block fitting 10.15mm 80.91


Using these measurements I worked out that the block fitting is the restriction on both setups, and that the Torque solution fitting is 26% smaller than the stock fitting.

But I have pulled out the AN setup
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Put the stock type turbo fitting back on
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And re-fit the stock head side fitting
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I just need to reconnect everything else, and hopefully it'll be happy, oil-leak free, smoke-free driving.
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Re: Member Profile - James' GT spec B Wagon - GTB013

Postby jamescd » Tue Mar 17, 2020 4:11 pm

I put the stock drain in, connected everything and couldn't help but notice that there was still oil leaking.

I noticed it was pooling on top of the engine and then leaking down near the turbo.
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Noticing that it was pooling right near the PCV hose I decided to quickly pull it off and give it a clean... 10 seconds later I had this
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I bought some hose and replaced the PCV hose and took it for a drive.

Still oil.

I noticed that it seemed to be slowly leaking from the crankcase breather port/hose.
So I pull that off... Again that leaves me with this
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Cooked solid and covered in oil
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So I replaced that.

Finally, I no longer pooled oil.
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Since then I have driven it to Cradle Mountain (4 hours with many hills)
It handled the drive well, but did smoke from the exhaust under high boost and under the bay was smokey when stopped after long hills.

I have a suspicion that the turbo seal is not as good as it once was after the kinked oil drain incident. I also suspect that the smoke in the bay is the up-pipe not sealing 100% (the v-bands are fiddly to get spot on) and the oil leaking through the turbo oil seals is burning on the exhaust and coming out through there.
On boost there is enough oil that it's noticeable out the exhaust, but up a hill is sustained enough to be noticeable in the bay.

Obviously a few things to look at still, but the car is at a point where I'm happy to drive it again.
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Re: Member Profile - James' GT spec B Wagon - GTB013

Postby bigBADbenny » Tue Mar 17, 2020 8:25 pm

Hook a spare boost gauge to your oil cap to check for positive crank case pressure on boost. :good:
Flatirons have a YouTube video regarding.
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